Prefabricated building panels and methods for constructing buildings

ABSTRACT

Example embodiments of the described technology provide a prefabricated building panel. The prefabricated panel may comprise a rigid insulative core having first and second opposing surfaces. A first cementitious material may at least partially cover the first surface of the insulative core. A second cementitious material may at least partially cover the second surface of the insulative core. At least one embedded element may extend along a peripheral edge of the insulative core.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit under 35 U.S.C. § 119 of U.S.application No. 63/212604 filed 18 Jun. 2021 and entitled PREFABRICATEDINSULATED BUILDING PANELS AND METHODS OF CONSTRUCTING BUILDINGS which ishereby incorporated herein by reference for all purposes.

FIELD

This invention relates to building panels and in particular cementitiousprefabricated building panels such as cementitious Structural InsulatedPanels (SIPs). Example embodiments provide prefabricated panels forachieving desired performance characteristics and methods forconstructing buildings with the prefabricated panels.

BACKGROUND

Constructing a building is typically an extensive project involvingsignificant amounts of time and/or resources (labour, energy, materials,etc.). Moreover, the carbon footprint of a building built using existingsystems and methods can be large.

Reducing the amount of time and/or resources required to construct abuilding can be desirable. Reducing the carbon footprint of a buildingcan also be desirable. With more environmentally stringent buildingcodes being passed regularly, reducing the amount of resources used toconstruct a building and the carbon footprint of the building isincreasingly becoming a requirement to be in compliance with newbuilding codes.

One way the amount of time and/or resources required can be reduced isby constructing the building using prefabricated panels. Existingprefabricated panels however are heavy, cannot provide the requiredperformance characteristics, etc. Additionally, existing prefabricatedpanels may be difficult to maneuver into place and to couple together.

There remains a need for practical and cost effective ways to constructprefabricated building panels using systems and methods that improve onexisting technologies.

SUMMARY

This invention has a number of aspects. These include, withoutlimitation:

-   -   non-load bearing prefabricated panels;    -   load bearing prefabricated panels;    -   prefabricated roofing panels;    -   methods for constructing a single story building;    -   methods for installing a roof of a building; and    -   methods for coupling prefabricated panels to a structure of a        building, such as a foundation and a metal framework installed        on the foundation.

Further aspects and example embodiments are illustrated in theaccompanying drawings and/or described in the following description.

It is emphasized that the invention relates to all combinations of theabove features, even if these are recited in different claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings illustrate non-limiting example embodiments ofthe invention.

FIG. 1A is a perspective view of a panel according to an exampleembodiment of the invention described herein.

FIG. 1B is a cross-sectional view of the panel of FIG. 1A.

FIG. 1C is a side view of the panel of FIG. 1A.

FIGS. 1D-1I are cross-sectional views of panels according to exampleembodiments of the invention described herein.

FIG. 1J is a partial cross-sectional view of a panel according to anexample embodiment of the invention described herein.

FIGS. 2A and 2B are perspective views of an example building constructedaccording to an example method of the invention described herein.

FIG. 3 is a block diagram illustrating a method for constructing abuilding according to an example embodiment of the invention.

FIGS. 3A-3F are perspective views of various steps of the method of FIG.3 .

FIG. 4A is a back view illustrating a coupling of a panel to astructural post according to an example embodiment of the inventiondescribed herein.

FIG. 4B is a side view and FIG. 4C is a perspective view of a connectoraccording to an example embodiment of the invention described herein.

FIG. 4D is a perspective view and FIG. 4E is a back view of a structuralpost according to an example embodiment of the invention describedherein.

FIGS. 4F to 4I are perspective views of example couplings of a panel toa structural post according to example embodiments of the inventiondescribed herein.

FIG. 4J is a schematic illustration showing example movement of astructural post relative to a panel which is coupled to the post duringa seismic event (or other exertion of force).

FIGS. 4K to 4M are perspective views of example couplings of panels toan underlying structure of a building according to example embodimentsof the invention described herein.

FIG. 5A is a perspective view of a brace-bay panel (or load bearingpanel) according to an example embodiment of the invention describedherein.

FIG. 5B is a front view of the panel of FIG. 5A.

FIG. 5C is a back view of the panel of FIG. 5A.

FIG. 5D is a cross-sectional view of the panel of FIG. 5A.

FIG. 5E is an exploded perspective view of the panel of FIG. 5A.

FIG. 6A is a perspective view of a roof panel according to an exampleembodiment of the invention described herein.

FIG. 6B is a cross-sectional view of the panel of FIG. 6A.

FIG. 6C is a perspective view of Q-deck sheeting of a prefabricatedpanel according to an example embodiment of the invention describedherein.

FIG. 7 is a block diagram illustrating a method according to an exampleembodiment of the invention described herein.

DETAILED DESCRIPTION

Throughout the following description, specific details are set forth inorder to provide a more thorough understanding of the invention.However, the invention may be practiced without these particulars. Inother instances, well known elements have not been shown or described indetail to avoid unnecessarily obscuring the invention. Accordingly, thespecification and drawings are to be regarded in an illustrative, ratherthan a restrictive sense.

One aspect of the technology described herein provides an exteriorcladding panel. A plurality of panels may be used to quickly andefficiently assemble exterior walls of a building under construction. Insome cases the cladding panel is coupled to an underlying structure thathas been assembled on site (e.g. a steel I-beam structure). In somecases the cladding panel is coupled to other pre-fabricated panels whichform part of the structure of the building under construction.Advantageously the cladding panel described herein may be coupled flushagainst structural posts, beams and/or the like.

The exterior cladding panel is preferably plant finished (e.g. fullymanufactured at a factory). A plurality of the exterior cladding panelsmay also preferably be easily and quickly shipped to a construction site(e.g. on a flatbed truck, within shipping containers, on railway cars,etc.). Once the panels arrive at the construction site they may beeasily and quickly assembled together.

FIG. 1A is a perspective view and FIG. 1B is a cross-sectional view ofan example cladding panel 10. Example panel 10 comprises an insulativecore 12 having opposing faces 12A and 12B. Insulative core 12 provides athermal break between face 10A and face 10B of panel 10. Insulative core12 may also at least partially structurally support panel 10. Insulativecore 12 may also at least partially dampen sound transmission throughpanel 10. Insulative core 12 preferably comprises a single piece ofinsulation. However, this is not necessary. In some embodimentsinsulative core 12 is made of two or more pieces of insulation.

In some embodiments insulative core 12 comprises rigid foam insulation.In some embodiments insulative core 12 comprises expanded polystyrene(EPS), polyisocyanurate (polyiso), extruded polystyrene (XPS) and/or thelike. In some embodiments insulative core 12 at least partiallycomprises mineral fiber rigid insulation.

In some embodiments insulative core 12 is at least about 3 inches thick(e.g. for warmer climates, etc.). In some embodiments insulative core 12is at least about 24 inches thick (e.g. to comply with passive housingstandards, for cold climates, etc.). In some embodiments insulative core12 is between 3 and 24 inches thick.

Insulative core 12 typically has an insulative R-value of about R4 perinch. In some embodiments insulative core 12 has an insulative R-valueof at least R12. In some embodiments insulative core 12 has aninsulative R-value of at least R96. In some embodiments insulative core12 has an insulative R-value between R12 and R96.

One or both of opposing surfaces 12A and 12B of insulative core 12 mayat least partially be covered by a cementitious material. For example,surface 12A may be covered by a cementitious layer 13A and surface 12Bmay be covered by a cementitious layer 13B (see e.g. FIG. 1 B). Inembodiments where both of surfaces 12A and 12B are covered by acementitious material, the same cementitious material need not coverboth of surfaces 12A and 12B (e.g. surface 12A may be covered by adifferent cementitious material than surface 12B).

In some embodiments one or both of surfaces 12A and 12B are covered bytwo or more different cementitious layers. In such embodiments thedifferent cementitious layers may have different properties. Forexample, one or both of surfaces 12A and 12B may each be covered withtwo or more different cementitious layers. A first one of thecementitious layers may be more fire resistant (e.g. comprises a morefire resistant cementitious material thereby increasing fire resistanceof panel 10) while a second one of the cementitious layers may bestructurally stronger (e.g. comprises a higher strength cementitiousmaterial thereby increasing structural strength of panel 10).

In some embodiments a cementitious material which covers at least one ofsurfaces 12A or 12B of insulative core 12 comprises a lower density(e.g. 5-35 megapascals (MPa)) cementitious material. The lower densitycementitious material may provide high fire protection characteristics(e.g. at least 2 hours at 1800 degrees Fahrenheit, is compliant withfire resistant standards (e.g. CAN/ULC-S101 Fire-Resistance Ratings,etc.) and/or the like). Additionally, or alternatively the lower densitycementitious material may provide high amounts of sound dampening (e.g.at least 50 STC (sound transmission class)).

In some embodiments a cementitious material which covers at least one ofsurfaces 12A or 12B of insulative core 12 comprises a higher density(e.g. 35-90 p MPa) cementitious material. The higher densitycementitious material may provide increased amounts of structuralstrength (e.g. a compressive strength in the range of about 120 to 160Pound-force per Cubic Foot (PCF)). In some embodiments the higherdensity cementitious material has a density in the range of about 90 to200 MPa and provides even higher amounts of structural strength.

As described above, in some embodiments at least one of surfaces 12A and12B of insulative core 12 is covered by both a lower densitycementitious layer and a higher density cementitious layer.

In some embodiments a cementitious material which covers at least one ofsurfaces 12A or 12B (or any other portion) of insulative core 12 iscurable. For example, the cementitious material may be poured or castover at least one of surfaces 12A or 12B (or any other portion) ofinsulative core 12 and cured. As the cementitious material cures, thecementitious material may bond directly to insulative core 12 (e.g.forming a “wet bond”).

As shown in FIG. 1 B, which is an example cross-sectional view of panel10, one or more side or peripheral edges 16 of panel 10 may comprise oneor more embedded elements 14. Side or peripheral edges 16 may, forexample, extend between surfaces 10A and 10B of panel 10. In someembodiments embedded elements 14 extend along all peripheral edges 16 ofpanel 10 (e.g. embedded elements 14 enclose the peripheral edges of core12). In some embodiments embedded elements 14 extend only along someedges 16 of panel 10.

The one or more embedded elements 14 may structurally couple opposingfaces 10A and 10B together with insulative core 12 thereby increasingoverall strength of panel 10. Additionally, or alternatively, the one ormore embedded elements 14 may provide a thermal break between opposingfaces 10A and 10B. Additionally, or alternatively, the one or moreembedded elements 14 may enclose insulative core 12 preventing leakageof insulative core 12 thereby improving fire resistance of panel 10(e.g. insulative core 12 may be flammable in liquid form).

In some embodiments connectors for coupling panel 10 to structuralelements of a building, to adjacent panels, and/or the like are coupleddirectly to one or more of the embedded elements 14. In some embodimentspanel 10 comprises a connector in each corner of panel 10. In someembodiments panel 10 comprises a connector in at least two corners ofpanel 10. In some embodiments one or more of the connectors are hidden(e.g. a person cannot readily see the connector when the panel isfinished or installed). In some embodiments one or more of theconnectors are flush with one or more surfaces of a panel (e.g. panel10).

Additionally, or alternatively, one or more hoisting points for liftingpanel 10 (e.g. with a crane) may be directly coupled to at least oneembedded element 14. In some embodiments one or more hoisting points arecoupled to at least one embedded element 14A. In some embodiments one ormore hoisting points are coupled to at least one embedded element 14B.In some embodiments one or more hoisting points are coupled to at leastone embedded element 14A and at least one embedded element 14B.

The one or more embedded elements 14 may comprise (non-limiting):

-   -   an extruded fibreglass channel (e.g. a C-shaped channel);    -   a custom fibreglass extrusion (e.g. shaped to incorporate        additional elements such as a dry seal gasket);    -   a steel or other metal channel (e.g. a C-shaped channel);    -   a structural steel or other metal (e.g. HSS, etc.) element;    -   a custom steel or other metal element;    -   custom aluminum, vinyl, PVC, steel, fibreglass, carbon fiber,        basalt or the like extrusions (preferably low or no thermal        conductivity);    -   combinations of any two or more of the above;    -   etc.

An embedded element 14 may span an entire edge of panel 10. However thisis not mandatory. In some embodiments an embedded element 14 onlypartially extends along an edge of panel 10. In some embodiments panel10 comprises no embedded elements 14.

Preferably an embedded element 14 has a low thermal conductivity (e.g.maintains thermal break between faces 10A and 10B of panel 10).

The example panel 10 shown in FIG. 1B comprises embedded elements 14comprising an extruded fibreglass channel 14A and a steel channel 14B.In such embodiments where panel 10 comprises both a fibreglass channeland a steel channel, connectors for connecting panel 10 to otherelements of a building under construction may be coupled directly tosteel channel 14B. In some embodiments both fibreglass channel 14A andsteel channel 14B extend along all peripheral edges of panel 10.

As described above, one or more of embedded elements 14 may comprise aC-shaped channel structure or the like. In some embodiments the open endof the C-shaped channel structure may face inwards towards insulativecore 12. In some embodiments the open end of the C-shaped channelstructure may face outwards away from insulative core 12. For example,the open ends of embedded elements 14 which extend along the top and/orbottom edges of panel 10 may face inwards to create flat edges. The openends of at least some of embedded elements 14 may, for example, faceoutwards along side edges of panel 10 (for better coupling against acolumn or post, to accommodate bolts which are present in a column orpost, etc.). In some embodiments the open end which faces outwards awayfrom insulative core 12 is filled with an insulative foam or the like.In some embodiments two adjacent embedded elements may have open endswhich face in opposite directions (see e.g. FIG. 1B).

FIG. 1C is a side view of example panel 10.

FIGS. 1 D-11 are schematic cross-sections of panel 10 illustratingdifferent example configurations of embedded elements 14. FIGS. 1D-1Fand 11 illustrate example embodiments where panel 10 comprises bothfibreglass channel 14A and steel channel 14B. FIG. 1G illustrates anexample embodiment where panel 10 comprises just a fibreglass channel14A. In such embodiments the fibreglass channel(s) 14A may provide astructural frame for such panel 10. FIG. 1H illustrates an exampleembodiment where panel 10 comprises a custom fibreglass channel 14Aconfigured to receive a sealing gasket 14C (e.g. a rubber gasket thatprovides a seal between two adjacent panels when they are coupledtogether).

In some embodiments a pin, mechanical fastener or the like may coupletwo adjacent embedded elements 14 together (see e.g. FIG. 1J whereexample pin 14D couples fibreglass channel 14A with steel channel 14B).

In some embodiments one or more pins, fasteners, rods, etc. extendthrough an embedded element 14 into cementitious material that is bonded(directly or indirectly) to insulative core 12. The one or more pins,fasteners, rods, etc. may, for example, increase the strength of thecoupling between the embedded element 14 through which the pin,fastener, rod, etc. extends through, the cementitious material and/orinsulative core 12.

One or more embedded elements 14 may also extend along edges of anaperture within panel 10 (e.g. a window or door opening). For example,both a fibreglass channel 14A and a steel channel 14B may extend arounda window or door opening. Preferably window or door frames being coupledto such panel 10 are secured to steel channel 14B due to the steelchannel's increased ability to withstand shear forces (e.g. wind shear,etc.). If steel channel 14B is embedded deeper than the window or doorframe, the window or door frame may, for example, be coupled to steelchannel 14B using an “L” shaped angle connector. In some embodiments awindow or door frame may be secured to fibreglass elements 14A (oranother embedded element 14). In some such embodiments elements 14A maytransfer load (e.g. wind shear, etc.) to a structural framework of panel10. In some embodiments elements 14A transfer load to elements 14B whichmay be adjacent or proximate to the elements 14A.

Panel 10 comprises reinforcing elements 15 (e.g. a mesh such as a weldedwire mesh, epoxy coated wire mesh, glass mesh and/or the like) which areembedded into the cementitious material covering surface 12A and/or 12Bof insulative core 12. Reinforcing elements 15 may extend from thecementitious material, pass under an embedded element (or elements) 14and into cementitious material on an opposing side of the embeddedelement (or elements). Reinforcing elements 15 may, for example,comprise an “S-like” shape (see e.g. FIGS. 1B-1G). In some embodiments acementitious material encloses reinforcing elements 15. In someembodiments pins, fasteners, rods, etc. which extend through an embeddedelement 14 increase the strength of the coupling between reinforcingelement 15 and the embedded element 14.

In some embodiments reinforcing element 15 and embedded element(s) 14are together fused to insulative core 12 (each of elements 15 andelements 14 may be individually or together fused to insulative core12). For example, reinforcing element 15 and embedded element(s) 14 maybe fused together to insulative core 12 with an adhesive or otherbonding agent and/or cementitious material. In some embodimentsreinforcing element 15 and embedded element(s) 14 are fused toinsulative core 12 with the cementitious material that covers a surfaceof insulative core 12. In some embodiments reinforcing element 15 andembedded element(s) 14 are fused together to insulative core 12 with anepoxy resin. In some embodiments a reinforcing element 15 is coupled toa surface (or surfaces) of an embedded element 14 (e.g. with a bondingagent (e.g. epoxy), a mechanical coupling method (e.g. fastening,weaving or sewing mesh onto surface (or surfaces) of embedded element14, etc.), etc.

By fusing reinforcing element 15 with embedded element(s) 14 andinsulative core 12 the strength of panel 10 may be increased in areas ofpanel 10 where reinforcing element 15 is present. Increasing thestrength of panel 10 in such areas of panel 10 facilitates having athinner insulative core 12 in those areas of panel 10. For example, itmay be desirable to have a thinner insulative core 12 (non-limiting):

-   -   along an interior edge of panel 10 to facilitate flush mounting        of the panel against a structural post (e.g. as shown in FIG. 1B        insulative core 12 is thinner in region 17 facilitating flush        mounting of the panel against a structural post (the structural        post may abut embedded element 14B proximate to region 17);    -   along an interior edge of panel 10 to facilitate flush mounting        of the panel against roof trusses, roofing panels or other roof        assemblies and/or the like (e.g. a parapet portion of panel 10        which may be adjacent a plurality of roof trusses may be thinner        than the remaining wall portion of panel 10 below the roof        trusses (see e.g. FIGS. 1A and 1C which illustrate upper portion        18 of panel 10 having a thinner insulative core)).

Insulative core 12 may, for example, be about 5%-35% thinner in areaswhere reinforcing element 15 is present compared to areas of insulativecore 12 where reinforcing element 15 is not present. In some embodimentsinsulative core 12 may be about 5%-80% thinner in areas wherereinforcing element 15 is present compared to areas of insulative core12 where reinforcing element 15 is not present. In some embodimentsinsulative core 12 is about 50% thinner in areas where reinforcingelement 15 is present compared to areas of insulative core 12 wherereinforcing element 15 is not present. In some embodiments insulativecore 12 is about 75% thinner in areas where reinforcing element 15 ispresent compared to areas of insulative core 12 where reinforcingelement 15 is not present.

In some embodiments an interior edge of panel 10 is custom shaped tomatch the profile of a post, beam or other structural element againstwhich panel 10 will be flush mounted when panel 10 is installed.

The cementitious layer on face 10A of panel 10 may comprise a decorativepattern (see e.g. FIG. 1A which illustrates a plurality of decorativegrooves 19). Face 10A of each panel 10 may, for example, correspond to acorresponding portion of the exterior of a building being constructed.As described elsewhere herein, panels 10 may generally be installed asexterior wall panels of a building under construction. However it is notnecessary that panel 10 correspond to an exterior wall panel in allcases.

FIGS. 2A and 2B are perspective views of an example single storycommercial building 20 which comprises panels 10. Although panels 10 maybe used in the construction of a single story commercial building 20,panels 10 may also be used for other buildings as well and should not belimited to the example case illustrated in FIGS. 2A and 2B.

FIG. 3 is a block diagram illustrating an example method 21 of erectingexample building 20.

In block 22 a plurality of prefabricated brace-bay panels (e.g.brace-bay panels 30) are coupled to a pre-built foundation 36 (see e.g.FIG. 3A). The brace-bay panels comprise a finished exterior surface aswell as embedded structural elements (e.g. structural posts, beams,cross-bracing, etc.). The brace-bay panels are load bearing and mayassist with dissipating shear forces (e.g. wind forces, seismic forces,etc.) which may be exerted on building 20. In some embodiments at leastone brace-bay panel is placed on each side of building 20 to assist withdissipating shear forces exerted on building 20.

The more load bearing panels (e.g. brace-bay panels) a buildingcomprises, the more uplift on a foundation of building 20 may belimited, enabling reduction of structural connections between buildingcomponents and the foundation and/or the like. For example, the moreload bearing panels are installed in a building the amount or size ofanchor rods that are required to be installed within the foundation atpoints where structural posts are coupled to the foundation may bereduced (e.g. less anchor rods, smaller diameter anchor rods, shorterlength anchor rods and/or the like). In some embodiments at least all ofthe exterior wall panels of a building are load bearing. In someembodiments all of the wall panels of a building are load bearing. Insome embodiments all of the load bearing wall panels comprise brace-baypanels.

In some embodiments building 20 comprises 10 or fewer brace-bay panels.In some embodiments building 20 comprises about 6 brace-bay panels. Insome embodiments building 20 comprises 5 or fewer brace-bay panels. Insome embodiments building 20 comprises at least one brace-bay panel. Insome embodiments building 20 comprises greater than 20 brace-bay panels.

In some embodiments a building comprises alternating load-bearing panels(e.g. brace-bay panels) and non-load-bearing panels (e.g. every secondpanel is a load-bearing panel). Cladding panel 10 is one example of anon-load-bearing panel. In some embodiments non-load-bearing panels suchas cladding panel 10 may comprise cross-bracing or other similarembedded structural elements. Such cross-bracing may increase thestructural strength of the non-load-bearing panels thereby requiringless underlying support structure. In some embodiments a cladding panel10 which comprises at least one embedded structural element may at leastpartially support load of the building it is installed in.

The pre-built foundation 36 may be constructed using any present orfuture construction practice for making building foundations. Forexample, concrete may be poured into forms to construct the foundation.A concrete base pad may then be poured over the foundation. As anotherexample, a foundation may be assembled using prefabricated panels. Asanother example, a foundation may be based on pilings which have beeninserted into the ground.

In block 23 vertical structural posts (posts 31) are coupled to thepre-built foundation. Structural posts 31 may comprise steel posts orthe like. Typically the distance between two adjacent posts 31 matchesthe width of a panel 10 which will be installed between the two adjacentposts.

In block 24 structural rim beams 32 are coupled to posts 31. Structuralrim beams 32 may, for example, comprise steel beams such as steel “I”beams. Rim beams 32 may support (e.g. provide a ledge, etc.) a roof ofthe building and/or transfer forces from the roof onto other componentsof the underlying structure of a building (e.g. posts, columns, etc.) tothe foundation of the building.

FIG. 3B illustrates the coupling of structural posts 31 and rim beams 32to building 20.

Trusses 33 may be coupled to rim beams 32 in block 25 (see e.g. FIG.3C). Trusses 33 may, for example, comprise steel trusses. In someembodiments trusses 33 comprise wood beams or the like. The number oftrusses 33 may be dependent on the width of roof panels 34 which will becoupled to trusses 33. The wider roof panels 34 are, the fewer trusses33 may be required in some cases.

In block 26 exterior cladding panels 10 are coupled to structural posts31 and rim beams 32 to form the exterior walls of building 20 (see e.g.FIG. 3E). In some cases panels 10 are coupled flush against structuralposts 31 and rim beams 32 (e.g. an interior wall formed by panel 10 isflush with an interior surface of post 31 and/or beam 32). In some casespanels 10 hang from one or both of post 31 and rim beam 32. For example,a panel 10 may comprise a header panel. The header panel may be coupledto hang from rim beam 32 (e.g. using angle connectors (e.g. L shapedconnectors) or the like).

In some cases panel 10 comprises a sill panel. The sill panel may becoupled to the pre-built foundation of building 20. For example, thesill panel may be coupled to the pre-built foundation of building 20using angle connectors (e.g. L shaped connectors) or the like.

Although panels 10 have been illustrated as being installed in block 26,panels 10 may be installed at any time after rim beams 32 have beeninstalled. In some cases installation of panels 10 is not continuous andother elements of building 20 may be installed intermittently. Forexample, trusses 33 or roof panels 34 may be installed intermittentlybetween installation of two panels 10. In some cases roof panels 34 areinstalled prior to installing cladding panels 10 (e.g. as shown in FIGS.3D and 3E).

A roof may be installed in block 27 (see e.g. FIG. 3D). Typically theroof comprises a plurality of pre-fabricated roof panels 34. However,this is not mandatory in all cases. In some embodiments a conventionalroof is installed (e.g. a base is built over trusses 33 and the base iscovered with a roofing material such as an asphalt membrane, shingles, asteel roof, etc.).

Windows and/or doors may be installed in block 28. In some cases howeverwindows and/or doors are installed upon a corresponding panel 10 beinginstalled. In some cases windows and/or doors are pre-installed withinpanels 10. Any remaining fixtures (awnings, canopies, decorative towers(e.g. decorative tower 37 shown in FIG. 3F), etc.) may be installed inblock 29.

As described elsewhere herein, panels 10 may be coupled to structuralposts 31. In some embodiments a panel 10 may be coupled to acorresponding post 31 as shown in FIG. 4A. A top end of panel 10 pay becoupled to a top end of post 31 with a connector 41. Connector 41 maycomprise a slot 42 as shown in FIGS. 4B and 4C. A bolt or other fastenermay pass through an aperture of post 31 and slot 42 to couple the topend of panel 10 to post 31.

As shown in FIGS. 4B and 4C connector 41 (or any other connector ofpanel 10) may be coupled to one or more embedded elements 14. Forexample, a connector may be coupled to embedded elements 14B. In someembodiments a connector is coupled to an embedded element 14 with boltsor other fasteners (e.g. bolts 48 shown in FIG. 4C).

A bottom end of panel 10 may be coupled to a corresponding bottom end ofpost 31 with a connector 43. Connector 43 may be the same as connector41 or different.

In some embodiments a middle portion of panel 10 may also be coupled topost 31 with a connector 45 as shown in FIG. 4A. This is not mandatoryin all cases. Connector 45 may comprise a slot through which a bolt orother fastener may pass through to couple the middle portion of panel 10to post 31.

As described elsewhere herein, in some embodiments one or more of theconnectors (e.g. connectors 41, 43, 45) are hidden (e.g. a person cannotreadily see the connector when the panel is finished or installed). Insome embodiments one or more of the connectors (e.g. connectors 41, 43,45) are flush with one or more surfaces of a panel (e.g. panel 10).

FIGS. 4D and 4E illustrate an example post 31.

FIG. 4F illustrates an example coupling of a panel 10 to a top portionof post 31. As another example, FIG. 4G illustrates an example couplingof a top part of a panel 10 to a post 31. FIG. 4H illustrates an examplecoupling of a panel 10 to a bottom portion of post 31. FIG. 4Iillustrates an example coupling a panel 10 to a middle portion of post31.

One or more of connectors 41, 43 and 45 may comprise a commerciallyavailable OrbiPlate™ coupling or the like (see e.g. FIG. 4H).

A connection of panel 10 to a post 31 (e.g. via a corresponding plate onthe post and a corresponding connector on the panel) may comprise atleast one bolt or other fastener passing through a slot. Such bolt andslot coupling may permit movement of post 31 relative to panel 10. Theslot may be part of the connector of panel 10, part of the correspondingplate of post 31 or part of both the connector of panel 10 and thecorresponding plate of post 31.

Advantageously, the slots of the connections between panels 10 to anunderlying structure of building 20 may permit members of the underlyingstructure of building 20 (e.g. a post 31, etc.) to pivot relative topanel(s) 10 during a seismic event (or other exertion of force onbuilding 20) or the like as shown in, for example, FIG. 4J. Permittingpivoting of members of the underlying structure of building 20 relativeto panel(s) 10 improves and maintains the structural integrity ofbuilding 20 during and after a seismic event (or upon the exertion ofany other force (or forces) which may cause an underlying structure ofbuilding 20 to move relative to panels 10). For example, a gap (e.g. gap47 shown in FIG. 4A) may be intentionally left between panel 10 and post31 such that post 31 can pivot relative to panel 10. In some embodimentsthe gap is less than about 1 inch. In some embodiments the gap is lessthan about 0.5 inches.

In some embodiments connector 43 also comprises a slot which permitsmovement of panel 10 relative to post 31.

FIG. 4K illustrates an example of a panel 10 (e.g. a sill panel) whichis coupled to posts 31 with angle connectors. As another example, FIG.4L illustrates an example of a panel 10 (e.g. a header panel) which iscoupled to an underlying structure of building 20 with angle connectors.FIG. 4M illustrates an example of a panel 10 which is coupled to a post31 with an angle connector and an OrbiPlate™ coupling.

In some embodiments a panel 10 comprises at least one post (e.g. post31) embedded within the panel. In some such embodiments rim beams (e.g.rim beams 32) and/or trusses (e.g. trusses 33) are exposed elements of abuilding.

FIG. 5A is a perspective view of an example load-bearing panel such asbrace-bay panel 30. FIG. 5B is an exterior front view of brace-bay panel30. FIG. 5C is an interior back view of brace-bay panel 30. FIGS. 5D and5E illustrate cross-sectional and exploded views respectively of examplebrace-bay panel 30.

Brace-bay panel 30 comprises an embedded structural frame 50 comprisingposts 51, a header beam 52 and cross-bracing 53 (optional). Differentembodiments of panel 30 may not comprise all of posts 51, beam 52 andcross-bracing 53. Posts 51 may be like structural posts 31. Header beam52 may be like rim beam 32. Cross-bracing 53 may comprise anycross-bracing between posts 51 and header beam 52. In the illustratedembodiment cross-bracing 53 comprises two beams (53A and 53B) which arediagonally arranged relative to one another to form an “X” like shape.In some embodiments cross-bracing 53 comprises beams 53A and 53Barranged in a chevron pattern (e.g. an upside down “V”). In someembodiments cross-bracing 53 comprises a single beam. In someembodiments cross-bracing 53 comprises three or more beams.

In some embodiments cross-bracing 53 may move freely relative to anycementitious layer of panel 30 (e.g. cross-bracing 53 may freely moveduring a seismic event relative to the cementitious layers which maycover panel 30). Allowing cross-bracing 53 to move freely mayadvantageously preserve the structural integrity of building 20,avoiding damage to panel 30 and/or the like.

Structural frame 50 is embedded within an insulative core 54 of panel30. Insulative core 54 may be like insulative core 12 of panel 10described elsewhere herein (e.g. may comprise an EPS foam or the like).Structural frame 50 may be coupled to insulative core 54 with acementitious material. The same or a different cementitious material mayat least partially cover one or both of faces 54A and 54B of insulativecore 54. In some embodiments a cementitious material (the same ordifferent than the cementitious material covering at least one of faces54A and 54B) covers at least a portion of structural frame 50. Suchcementitious material(s) may have any one or more of the characteristicsand/or properties of cementitious materials described herein.

Plates 55 may be coupled to bottom ends of posts 51. Plates 55 may, forexample, comprise apertures 56 through which bolts may pass through. Thebolts may be inserted into corresponding apertures in the buildingfoundation thereby coupling panel 30 to the building foundation.

In some embodiments brace-bay panel 30 is like cladding panel 10described elsewhere herein except that brace-bay panel 30 additionallycomprises an embedded structural frame 50.

As described elsewhere herein, a plurality of roof panels 34 may form aroof of building 20. In some embodiments roof panels 34 compriseprefabricated panels having an insulative core as described elsewhereherein (e.g. an EPS foam core or other suitable material) and at leastone surface of the insulative core at least partially covered by acementitious material. Such cementitious material may have any one ormore of the characteristics and/or properties of cementitious materialsdescribed herein. In some embodiments roof panel 34 is like the panelshown in FIGS. 6A and 6B.

FIG. 6A is a perspective view of an example composite roof panel 34.FIG. 6B is a cross-sectional view of composite roof panel 34.

Panel 34 comprises an insulative core 62 (e.g. an EPS foam or othermaterial as described elsewhere herein). Q-deck sheeting 63 may becoupled to a surface 62A of core 62 with a cementitious material 64. Insome embodiments an inner surface 63A of Q-deck sheeting 63 comprisestexture features 65 (e.g. holes, bumps, ridges, etc.) as shown in FIG.6C. Textured features 65 may facilitate bonding of cementitious material64 to Q-deck sheeting 63. Q-deck sheeting 63 typically comprises metalsheeting. In some embodiments Q-deck sheeting 63 comprises steelsheeting. Cementitious material 64 may have any one or more of thecharacteristics and/or properties of cementitious materials describedherein.

In some embodiments only about ¼ inch of cementitious material between atop surface of Q-deck sheeting 63 and surface 62A is required toproperly bond Q-deck sheeting 63 to core 62. In some such embodimentsroof panel 34 has a total weight that is less than about 20 pounds persquare foot.

In some embodiments not every trough of Q-deck sheeting 63 is filledwith cementitious material 64. For example, every second trough may beunfilled (e.g. the troughs alternate between filled and unfilled). Bynot filling every trough of Q-deck sheeting 63, an overall weight ofroof panel 34 may be reduced. Foam inserts (e.g. Styrofoam, EPS, etc.)or similar may be placed in the unfilled troughs. Cementitious material64 may bond together all of Q-deck sheeting 63, the foam inserts andinsulative core 62 to form the composite roof panel 34.

Opposing surface 62B of core 62 may be covered by a weather-resistantroofing element or roofing membrane. In some embodiments surface 62B iscovered by a cementitious material. In some embodiments surface 62B iscovered by a commercially available roofing membrane. In someembodiments the roofing membrane extends past outer edges of surface 62Bof panel 34 (e.g. past two edges of surface 62B). When adjacent panels34 are coupled together, the roofing membrane which extends past theedges of surface 62B may be placed over surface 62B of the adjacentpanel 34. The overlapping roofing membranes may be joined together (e.g.welded, bonded, etc.) to seal the roofing membrane. Extending a roofingelement over an adjacent panel may improve the quality of the sealbetween adjacent panels 34 thereby reducing the likelihood of any leaksforming. Typically the roofing elements or portions of the membrane aresealed such that higher roofing elements or portions of the membrane areplaced over lower roofing elements or portions of the membrane. In someembodiments the roofing element or membrane extends past the back andright edges of a panel 34 (not mandatory).

In some embodiments surface 62B of insulative core 62 is shaped todirect water in a desired manner. For example, surface 62B may be slopeddownwards from one end to an opposing end of panel 34. As anotherexample, surface 62B may be shaped as a “V”.

In some embodiments one or more roof panels 34 comprise one or moredrainage ports to direct water away from the roof surface. In someembodiments surface 62B may be shaped to direct water towards thedrainage port(s). In some embodiments surface 62B comprises atrough-like channel to direct water towards the drainage port.

In some embodiments panel 34 may be coupled to building 20 by weldingportions of Q-deck sheeting 63 to roof trusses 33 or the like. In someembodiments panel 34 may be coupled to building 20 by fastening panel 34to building 20. For example, panel 34 may be fastened to one or more oftrusses 33, rim beams 32, posts 31 and/or panels 10 or 30. In someembodiments adjacent panels 34 may be coupled (e.g. by fastening)together. In some embodiments panel 34 comprises one or more connectorsembedded within and/or coupled to insulative core 62. For example, panel34 may comprise a connector in each corner of panel 34. At least one ofthe connectors may be used to hoist or lift panel 34. Such connectorsmay be flush with one or more surfaces of the panel as describedelsewhere herein.

In some embodiments Q-deck sheeting 63 is about 18-22 gauge. Typicallythe longer the span between trusses (e.g. trusses 33) the lower thegauge of Q-deck sheeting 63 is.

Q-deck sheeting 63 may, for example, be about 2 feet wide and about24-30 feet long. Such Q-deck sheeting may have troughs or corrugationswhich are about 3 inches deep. Panels 34 in such cases may, for example,be about 8, 10 or 12 feet wide and about 24-30 feet long.

As another example, Q-deck sheeting 63 may be about 3 feet wide andabout 24-30 feet long. Such Q-deck sheeting may have troughs orcorrugations which are about 2 inches deep. Panels 34 in such cases may,for example, be about 9 feet wide and about 24-30 feet long.

FIG. 7 is a block diagram illustrating an example method formanufacturing a roof panel (e.g. roof panel 34).

In block 71 Q-deck sheeting (e.g. Q-deck sheeting 73) is placed into aform. Optionally, inserts (e.g. the foam inserts described elsewhereherein) may be placed in troughs or corrugations of the Q-deck sheetingwhich are not to be filled with the cementitious material in block 72.

Cementitious material is poured over the Q-deck sheeting in block 73. Aninsulative core (e.g. insulative core 62) may be placed over the pouredcementitious material in block 74. In some embodiments the cementitiousmaterial is allowed to partially set prior to placing the insulativecore.

If an opposing surface of the insulative core is sloped or otherwiseshaped to direct water in a desired manner, the form may bere-positioned such that the opposing surface of the insulative core islevel (e.g. forms a straight line) in block 75.

In some embodiments a block or the like is positioned under one end ofthe form (e.g. the end of the form to be raised). In some embodimentsthe components of the panel already in the form are allowed to set andthen an end of the Q-deck sheeting is raised directly (e.g. by placing ablock under the Q-deck sheeting.

In block 76 a cementitious material is poured over the opposing surfaceof the insulative core. The cementitious material may be the same ordifferent than the cementitious material poured in block 73.

A roofing membrane or roofing elements may be coupled to the opposingsurface of the insulative core in block 77. In some embodiments thecementitious layer poured in block 76 couples the roofing membrane orroofing elements to the insulative core. In some embodiments thecementitious layer poured in block 76 is allowed to partially set priorto coupling the roofing membrane or roofing elements.

Although roof panel 34 has been described in the context of a roof for asingle story commercial building (e.g. building 20), roof panel 34 maybe used to construct any roof of a building. Roof panel 34 may, forexample, be used to build a roof of a commercial building, residentialbuilding, industrial building, mixed commercial and residentialbuilding, etc. In some cases roof panels 34 are used to construct a rooffor a building that does not otherwise use prefabricated building panels(e.g. a building which was built according to alternative constructionpractices except for the roof). In some cases roof panels 34 are used toretrofit any existing roof of a building.

As described elsewhere herein brace-bay panel 30 may comprise astructural frame 50. Such structural frame may be partially or fullycovered by cementitious material. In some embodiments one or morecladding panels 10 comprise a structural frame or structural elements(e.g. one or more of structural posts, rim beams, cross-bracing, etc.).The structural frame or structural elements of a cladding panel 10 mayat least partially be covered by cementitious material. In embodimentswhere cementitious material covers at least partially a structural frameor structural element of a panel, the structural frame or structuralelement may be able to move relative to the cementitious material. Insome such embodiments the structural frame or structural element may bede-coupled from the cementitious material. The cementitious material mayhowever prevent the structural frame or structural element(s) frommoving relative to the insulative core by more than a threshold amount.

The systems and methods described herein may include coupling variousprefabricated panels together. Joints between adjacent ones of theprefabricated panels may be sealed. In some embodiments the joints aresealed in a manner that matches a surrounding facade. In someembodiments the joints are sealed using a commercially availableexpanding foam (e.g. a spray foam) or caulking substance.

In some embodiments adjacent panels are welded together. In someembodiments one or more panels are welded to a structure of thebuilding.

Interpretation of Terms

Unless the context clearly requires otherwise, throughout thedescription and the claims:

-   -   “comprise”, “comprising”, and the like are to be construed in an        inclusive sense, as opposed to an exclusive or exhaustive sense;        that is to say, in the sense of “including, but not limited to”;    -   “connected”, “coupled”, or any variant thereof, means any        connection or coupling, either direct or indirect, between two        or more elements; the coupling or connection between the        elements can be physical, logical, or a combination thereof;    -   “herein”, “above”, “below”, and words of similar import, when        used to describe this specification, shall refer to this        specification as a whole, and not to any particular portions of        this specification;    -   “or”, in reference to a list of two or more items, covers all of        the following interpretations of the word: any of the items in        the list, all of the items in the list, and any combination of        the items in the list;    -   the singular forms “a”, “an”, and “the” also include the meaning        of any appropriate plural forms.

Words that indicate directions such as “vertical”, “transverse”,“horizontal”, “upward”, “downward”, “forward”, “backward”, “inward”,“outward”, “left”, “right”, “front”, “back”, “top”, “bottom”, “below”,“above”, “under”, and the like, used in this description and anyaccompanying claims (where present), depend on the specific orientationof the apparatus described and illustrated. The subject matter describedherein may assume various alternative orientations. Accordingly, thesedirectional terms are not strictly defined and should not be interpretednarrowly.

While processes or blocks are presented in a given order, alternativeexamples may perform routines having steps, or employ systems havingblocks, in a different order, and some processes or blocks may bedeleted, moved, added, subdivided, combined, and/or modified to providealternative or subcombinations. Each of these processes or blocks may beimplemented in a variety of different ways. Also, while processes orblocks are at times shown as being performed in series, these processesor blocks may instead be performed in parallel, or may be performed atdifferent times.

In addition, while elements are at times shown as being performedsequentially, they may instead be performed simultaneously or indifferent sequences. It is therefore intended that the following claimsare interpreted to include all such variations as are within theirintended scope.

Where a component (e.g. an insulative core, connector, structural post,etc.) is referred to above, unless otherwise indicated, reference tothat component (including a reference to a “means”) should beinterpreted as including as equivalents of that component any componentwhich performs the function of the described component (i.e., that isfunctionally equivalent), including components which are notstructurally equivalent to the disclosed structure which performs thefunction in the illustrated exemplary embodiments of the invention.

Specific examples of systems, methods and apparatus have been describedherein for purposes of illustration. These are only examples. Thetechnology provided herein can be applied to systems other than theexample systems described above. Many alterations, modifications,additions, omissions, and permutations are possible within the practiceof this invention. This invention includes variations on describedembodiments that would be apparent to the skilled addressee, includingvariations obtained by: replacing features, elements and/or acts withequivalent features, elements and/or acts; mixing and matching offeatures, elements and/or acts from different embodiments; combiningfeatures, elements and/or acts from embodiments as described herein withfeatures, elements and/or acts of other technology; and/or omittingcombining features, elements and/or acts from described embodiments.

Various features are described herein as being present in “someembodiments”. Such features are not mandatory and may not be present inall embodiments. Embodiments of the invention may include zero, any oneor any combination of two or more of such features. This is limited onlyto the extent that certain ones of such features are incompatible withother ones of such features in the sense that it would be impossible fora person of ordinary skill in the art to construct a practicalembodiment that combines such incompatible features. Consequently, thedescription that “some embodiments” possess feature A and “someembodiments” possess feature B should be interpreted as an expressindication that the inventors also contemplate embodiments which combinefeatures A and B (unless the description states otherwise or features Aand B are fundamentally incompatible).

It is therefore intended that the following appended claims and claimshereafter introduced are interpreted to include all such modifications,permutations, additions, omissions, and sub-combinations as mayreasonably be inferred. The scope of the claims should not be limited bythe preferred embodiments set forth in the examples, but should be giventhe broadest interpretation consistent with the description as a whole.

What is claimed is:
 1. A prefabricated building panel, the panelcomprising: a rigid insulative core having first and second opposingsurfaces; a first cementitious material at least partially covering thefirst surface of the insulative core; a second cementitious material atleast partially covering the second surface of the insulative core; andat least one embedded element extending at least partially along aperipheral edge of the insulative core.
 2. The panel as defined in claim1, wherein the at least one embedded element extends at least partiallybetween the first and second opposing surfaces.
 3. The panel as definedin claim 1, wherein the at least one embedded element is selected fromthe group consisting of a fibreglass channel, a metal channel, afibreglass extrusion, an aluminum extrusion, a vinyl extrusion, a PVCextrusion, a steel extrusion, a carbon fiber extrusion and a basaltextrusion.
 4. The panel as defined in claim 3, wherein the at least oneembedded element is generally C-shaped and comprises a wall section andan open end defining a channel.
 5. The panel as defined in claim 1,wherein the at least one embedded element comprises a fibreglass channelor fibreglass extrusion.
 6. The panel as defined in claim 5, wherein theat least one embedded element further comprises a metal channel.
 7. Thepanel as defined in claim 6, wherein the wall section of the fibreglasschannel is aligned with the wall section of the metal channel.
 8. Thepanel as defined in claim 6, wherein the wall section of the fibreglasschannel is offset from the wall section of the metal channel.
 9. Thepanel as defined in claim 4, wherein the at least one embedded elementcomprises a first embedded element and a second embedded element, andwherein the open ends of the first and second embedded elements areoriented in the same direction.
 10. The panel as defined in claim 4,wherein the at least one embedded element comprises a first embeddedelement and a second embedded element, and wherein the open ends of thefirst and second embedded elements are oriented in opposite directions.11. The panel as defined in claim 3, wherein the at least one embeddedelement is a fibreglass extrusion shaped to receive a seal.
 12. Thepanel as defined in claim 11, wherein the seal is a dry seal gasket. 13.The panel as defined in claim 1, comprising at least one reinforcingelement located proximate to the at least one embedded element tostrengthen the panel in the vicinity of the at least one embeddedelement.
 14. The panel as defined in claim 13, wherein the thickness ofthe insulative core is reduced in a first region of the panel in thevicinity of the embedded element in comparison to a second region of thepanel removed from the embedded element.
 15. The panel as defined inclaim 13, wherein the at least one reinforcing element is a wire mesh.16. The panel as defined in claim 15, wherein the wire mesh is selectedfrom the group consisting of a welded wire mesh, an epoxy coated wiremesh, and a glass mesh.
 17. The panel as defined in claim 13, whereinthe reinforcing element is generally S-shaped.
 18. The panel as definedin claim 13, wherein the at least one reinforcing element and the atleast one embedded element are individually or together fused to theinsulative core.
 19. The panel as defined in claim 18, wherein the atleast one reinforcing element and the at least one embedded element areindividually or together fused to the insulative core with an adhesiveor other bonding agent.
 20. The panel as defined in claim 18, whereinthe at least one reinforcing element and the at least one embeddedelement are individually or together fused to the insulative core withan epoxy resin.
 21. The panel as defined in claim 18, wherein the atleast one reinforcing element and the at least one embedded element areindividually or together fused to the insulative core with acementitious material.
 22. The panel as defined in claim 13, wherein theat least one reinforcing element extends into one or more of the firstcementitious material and the second cementitious material in thevicinity of the at least one embedded element.
 23. The panel as definedin claim 22, wherein the at least one reinforcing element extendsbetween the first cementitious material and the second cementitiousmaterial.
 24. The panel as defined in 14, wherein the first region ofthe panel is configured to be flush-mounted to a support structure. 25.The panel as defined in claim 1, wherein the at least one embeddedelement stiffens the panel along the peripheral edge.
 26. The panel asdefined in claim 1, wherein the at least one embedded element provides athermal break between the first and second opposing faces.
 27. The panelas defined in claim 1, wherein the at least one embedded element atleast partially encloses the insulative core to enhance the fireresistance of the panel.
 28. The panel of claim 1, wherein theinsulative core is thinner on one side of the peripheral edge than theother side of the peripheral edge.
 29. A composite prefabricatedload-bearing panel, the panel comprising: a rigid insulative core havingfirst and second opposing surfaces; a first structural post at leastpartially embedded on a first side of the insulative core; a secondstructural post at least partially embedded on a second side of theinsulative core, the second side opposite the first side; a beamextending from an upper portion of the first post to an upper portion ofthe second post, the beam at least partially embedded in the insulativecore; a first cementitious material at least partially covering thefirst surface of the insulative core; and a second cementitious materialat least partially covering the second surface of the insulative core;wherein the first and second cementitious materials at least partiallybond the insulative core, the first and second structural posts and thebeam together.
 30. The panel of claim 29 further comprisingcross-bracing coupled to at least two of the first post, the second postand the beam.
 31. The panel of claim 30 wherein the cross-bracing isX-shaped.
 32. The panel of claim 30 wherein the cross-bracing ischevron-shaped.
 33. The panel of claim 29, wherein at least one of thefirst post, the second post, the beam and the cross-bracing may moverelative to one or both of the first and second cementitious materials.34. An assembly comprising a first non-load bearing panel and a secondload-bearing panel, wherein the first non-load-bearing panel comprises:a rigid insulative core having first and second opposing surfaces; afirst cementitious material at least partially covering the firstsurface of the insulative core; a second cementitious material at leastpartially covering the second surface of the insulative core; and atleast one embedded element extending at least partially along aperipheral edge of the insulative core.
 35. The assembly as defined inclaim 34, wherein the first non-load bearing panel is mechanicallyconnected to the second load-bearing panel.
 36. The assembly as definedin claim 35, wherein the second load-bearing panel comprises embeddedstructural elements, wherein the embedded structural elements areselected from the group consisting of structural posts, beams andcross-bracing.
 37. The assembly as defined in claim 34, wherein thesecond load-bearing panel comprises: a second rigid insulative corehaving first and second opposing surfaces; a first structural post atleast partially embedded on a first side of the second insulative core;a second structural post at least partially embedded on a second side ofthe second insulative core, the second side opposite the first side; abeam extending from an upper portion of the first post to an upperportion of the second post, the beam at least partially embedded in thesecond insulative core; a third cementitious material at least partiallycovering the first surface of the second insulative core; and a fourthcementitious material at least partially covering the second surface ofthe second insulative core; wherein the third and fourth cementitiousmaterials at least partially bond the second insulative core, the firstand second structural posts and the beam together.
 38. The assembly asdefined in claim 34, wherein the first non-load bearing panel and thesecond load-bearing panel are pre-fabricated.
 39. The assembly asdefined in claim 37, wherein the first non-load bearing panel and thesecond load-bearing panel are pre-fabricated.
 40. A building comprisinga plurality of wall components, wherein at least some of the wallcomponents comprise: (a) a panel comprising: a rigid insulative corehaving first and second opposing surfaces; a first cementitious materialat least partially covering the first surface of the insulative core; asecond cementitious material at least partially covering the secondsurface of the insulative core; and at least one embedded elementextending at least partially along a peripheral edge of the insulativecore; and/or (b) a panel comprising: a second rigid insulative corehaving first and second opposing surfaces; a first structural post atleast partially embedded on a first side of the second insulative core;a second structural post at least partially embedded on a second side ofthe second insulative core, the second side opposite the first side; abeam extending from an upper portion of the first post to an upperportion of the second post, the beam at least partially embedded in thesecond insulative core; a third cementitious material at least partiallycovering the first surface of the second insulative core; and a fourthcementitious material at least partially covering the second surface ofthe second insulative core; wherein the third and fourth cementitiousmaterials at least partially bond the second insulative core, the firstand second structural posts and the beam together; and/or (c) anassembly as defined in claim
 34. 41. The building as defined in claim40, wherein at least some of the structural framework of the building isselected from the group consisting of columns, posts, beams, anchors,bracing, and frames is embedded within the panel(s) and/or the assembly.42. A prefabricated composite roofing panel, the panel comprising: arigid insulative core; and Q-deck sheeting coupled to a first surface ofthe insulative core with a cementitious material.
 43. The panel of claim42, wherein inner surfaces of the Q-deck sheeting which oppose the firstsurface of the insulative core comprise one or more textured elements.44. The panel of claim 42, wherein the textured elements increase a bondstrength of the cementitious material with the Q-deck sheeting.
 45. Thepanel as defined in claim 42, wherein the Q-deck sheeting comprises aplurality of troughs, wherein only some of the troughs are filled withthe cementitious material.
 46. The panel as defined in claim 42, whereinthe thickness of the cementitious material located above the innersurface of the Q-deck sheeting immediately adjacent the first surface ofthe insulative core is less than 0.5 inches.
 47. The panel as defined inclaim 46, wherein the thickness of the cementitious material isapproximately 0.25 inches.
 48. The panel as defined in claim 42,comprising a roofing element coupled to a second surface of theinsulative core, the second surface opposite the first surface.
 49. Thepanel as defined in claim 48, wherein the roofing element comprises acementitious material.
 50. The panel as defined in claim 48, wherein theroofing element comprises a weather-resistant roofing membrane.
 51. Thepanel as defined in claim 48, wherein the roofing element extends pastouter edges of the second surface of the insulative core for overlappingwith adjacent roofing panels or other adjacent structures when the panelis installed.
 52. The panel as defined in claim 48 wherein the secondsurface of the insulative core is shaped to direct water according to adesired specification.
 53. The panel as defined in claim 52 wherein theinsulative core is wedge-shaped.
 54. The panel as defined in claim 42,wherein the panel has a weight that is less than about 20 pounds persquare foot.
 55. A building assembly comprising: a foundation; and aload bearing panel coupled to the foundation, the panel providing ashear wall for the building, the panel comprising: a rigid insulativecore having first and second opposing surfaces; a first structural postat least partially embedded on a first side of the insulative core; asecond structural post at least partially embedded on a second side ofthe insulative core, the second side opposite the first side; a beamextending from an upper portion of the first post to an upper portion ofthe second post, the beam at least partially embedded in the insulativecore; a first cementitious material at least partially covering thefirst surface of the insulative core; and a second cementitious materialat least partially covering the second surface of the insulative core;wherein the first and second cementitious materials at least partiallybond the insulative core, the first and second structural posts and thebeam together.
 56. The building assembly of claim 55 further comprisinga non-load bearing panel, the non-load bearing panel comprising: asecond rigid insulative core having first and second opposing surfaces;a third cementitious material at least partially covering the firstsurface of the second insulative core; a fourth cementitious material atleast partially covering the second surface of the second insulativecore; and at least one embedded element extending at least partiallyalong a peripheral edge of the second insulative core.
 57. The buildingassembly of claim 56 wherein the non-load bearing panel is coupled tothe load-bearing panel.
 58. The building assembly of claim 55 whereinthe non-load bearing panel is coupled to a structural post of thebuilding assembly, the structural post coupled to the foundation. 59.The building assembly of claim 58 wherein a surface of the non-loadbearing panel is coupled generally flush against the structural post.60. The building assembly of claim 55 comprising a roof panel, the roofpanel comprising: a third rigid insulative core; and Q-deck sheetingcoupled to a first surface of the third insulative core with a fifthcementitious material.
 61. A building, the building comprising: astructural post coupled to a foundation; and a panel according to claim1, the panel coupled to the structural post, the structural postpivotable relative to the panel.
 62. The building of claim 61 whereincoupling the panel to the structural post leaves a gap between thestructural post and the panel.